Battery case and terminal post construction



Aug. 26, 1952 J. E. wHn-E BATTERY CASE AND TERMINAL PosT CONSTRUCTIONFiled March 18, 1947 l l l INVENTOR JOVHN EDWARD WHITE BY w 0n/7W aATTORNEY Aug. 26, A1952 J. E. WHITE 2,608,596

BATTERYTASE AND TERMINAL PosT CONSTRUCTION Filed March 18, 1947 2SHEETS-SHEET 2 F-l's- 12 INVENTOR JOHN EDWARD WHITE MYWW ATTORNEYPatented Aug. 26, 1952 UNITED 1 STATES PATENT OFFICE BATTERY CASE ANDTERMINAL PGST CONSTRUCTION John Edward White, Philadelphia, Pa.,assignor to The Electric Storage Battery Company, a corporation of NewJersey Application March 18, 1947, Serial No. 735,363

(Cl. 13G-166) 12 Claims. 1 This invention relates to improvements instorage batteries and particularly to improvements in storage batterycases and terminal post constructions.

Objects of the invention are to provide improved storage batterycases inwhich both jar and cover are formed Vfrom two preferably identically`molded, mating casehalves, and to provide improved terminal postconstructions particularly adapted r for batteries having casesformedinsuch fashion. l

Further objects ofthe invention are to provide improved battery casesAformed by cementing together two sections of plastic material, the seambetween the sections being Aimpervious to electrolyte; to provideimproved battery cases in which the need for separate jars and covers iseliminated, thereby reducing the number of dif-` ferent designs of`parts needed; to provide improved and simplified methodsof assemblingstorage batteries, and to provide improved battery case constructions inwhich cases enclosing a plurality of cells of any desired number may beformed from two mating .-,case sections, preferably identically moldedhalves. I

In accomplishing these and other objects of the present invention, Ihaveprovided improved details oi structure,preferredl forms of which areshown in the accompanying drawings, wherein:

Figure l is a side elevational view of a storage battery constructed inaccordance with the principles of the present invention, a portion ofone of the case sections being broken away to clarify the illustration;r i, v

Figure 2 is an exploded top plan view of two battery case sectionsconstructed in accordance with the present invention and two batteryelements, illustrating the fashion in which the case sections andelements Vare assembled;

Figure 3 is a horizontalsectional View illustrating a gravity indicatorthat may be employed in the battery, the view beingtaken substantiallyon the line 3 3 of Figure 1;

Figure 4 is a horizontal sectional View, similar to Figure 3, butshowing a modified form of gravity indicator;

Figure 5 is a side elevational view of a portion of a battery showing amodied form of terminal post, post seal, and intercell connector, aportion of one of the case sections being broken away to clarify theillustration; l

Figure 6 is a vertical sectional view taken substantially on the line 66 of Figure 5 Figure 7 is a horizontal sectionalview taken substantiallyon the` line A'I,-1 of Figure 5;

Figure 8 is an enlarged perspective view of a Wedge employed in the postseal construction shown in Figures 5, 6 and 7;

Figure 9 is a side elevational view of a portion of a case section andterminal post showing a further modified form of post and post seal;

Figure 10 is an enlarged perspective view of a plastic collar halfemployed in-the post seal of Figure 9; l

Figure 11 is a side elevational view of a portion of a case section andintercell connector showing still another modified form of terminalpost, post seal and intercell connector; and

Figure 12 is a vertical sectional view taken substantially on the lineI2-I2 of Figure l1, the battery element being omitted.

Referring more in detail to the drawings:

Figures l and 2` illustrate in detail a two cell storage battery inwhich the case and terminal posts are constructed in` accordance withone form of the present invention. `The battery, designated I, comprisesa case I I, assembled elements having the usual positive and negativeplates I2 and separators I3, positive and negative terminals I4 and I5respectively, intercell connector I6 and vent caps II and I8. r

In accordance with the present invention, the easel IV is formed of twoidentically molded, mating case halves I9 and 2D. The case halves arepreferably molded from a synthetic resinous material that is chemicallyresistant to the electrolyte and capable of being cemented, as, forexample, polystyrene, vinyl polymers or copolymers, polyethylene ormethacrylates. In the construction shown the casehalves are identical inall respects and only the case half I9 is described in detail; it is tobe understood that the case half 20 has the same structural features.

The case half I9 includes a side wall 2I, end wall halves 22 and 23,bottom half 24, cover half 25 and partition half 2li, all moldedintegrally by i any suitable molding process. Laterallyextendingseparator or element supporting ribs 21 and 28 are upstandingfrom bottom 24, and element packing members 29 project from side wall2l, all molded integrally withl the respective wall portions. y r

The inner edge oi cover halfl 25 has four semicircular recesses 3|, 32,33 and 34 for reception of terminal'posts, and two additional recesses35 and formed as halves of threaded sockets, here illustrated asinterrupted threads of the bayonet type. `The recesses are positionedsymmetrically `with respect to the transverse vertical center cularapertures or threaded sockets. Preferably surrounding recesses 3| to 36in the cover half are upstanding flanges 3Ia, to 36a respectively, eachforming half of an annulus, as illustrated in Figure 2.

In the form illustrated the case half has vertically extending troughs31 and 38 projecting outwardly from the inner edge of end walls 22 and23 for reception of gravity indicators.

The edges of the end walls between the troughs and the case interior arerecessed, as indicated at 39, to permit entrance of the electrolyte intothe troughs (see Figures 1 and 3). The gravity indicating devices mayconveniently be masses or shapes 46 of known specic gravity, the gravityof the shapes which Boat in the electrolyte indicating the gravity ofthe electrolyte in the manner known in the art.

As best shown in Figure 2, the rst steps in assembling a battery inwhich the case is formed in accordance with the present invention are toinsert assembled elements into one of the case halves, in this instancecase half 20, and to insert gravity shapes 4U into the troughs or" saidcase half. Appropriate cement, resistant to electrolyte, is then appliedto the case halves at the edge faces that are to Contact each other. Asolution of the synthetic resin from which the case halves are made issuitable for such a cement. Case half I9 is then placed overtheelements, and is secured to case half by the adhesive action of thecement. By this cementing operation the seams between the case halves',both in the external walls of the case and in the partition betweencells, are made impervious to electrolyte.

The separators are supported on ribs 21 and 2S in the constructionshown, and the spaces at either side of said ribs furnish spaces intowhich sediment may drop. The plate groups are supported by suspensionfrom the battery cover and the assembled elements are compressed bypacking members 2S. In other designs, the plates as well as separatorsmay be supported on ribslo- Y cated as 21 and 28.

The element on the left as viewed Yin Figure 2 has a negative terminalpost 4I and positive terminal post 42, and the element on the right hasa negative terminal post 43 and positive terminal post 44. The batteryelements are not described in further detail since elements of anysuitable type may be employed in batteries having case and terminal postconstructions of the present invention. When the battery is assembled,posts 4I', 42, 43 and 44 are received respectively in the aperturesformed in the cover by the mating of semi-circular recesses 3|, 32, 33and 34 in case half I9 with corresponding recesses in case half 20.

The posts shown in Figures 1 and 2 have a plurality of integrally castradial lugs 45 adapted to engage the under surface of the cover halves.Above the cover each post has a screw threaded section 46 which receivesa nut 41, a washer 48 of resilient or compressible material beinginterposed between each nut 41 and the cover. In assembling the battery,nuts 41 and washers 48 may be applied to the posts before assembly ofthe elements and case halves, as illustrated in Figure 2, and tightenedafter assembly, the iianges around the edges of the recesses beingreceived between the washers and the tops of lugs 45. Otherwise, if itis more convenient, the nuts and washers may be appliedafter assembly ofthe elements and case halves.

After the battery has been assembled as deliianges 54 and 55 the shankof each 4 scribed, battery terminals I4 and I5 are applied to posts 4Iand 44 and intercell connector I6 to posts 42 and 43. The terminals andconnector may be of any appropriate design and may be secured to theposts either before or after assembly `of the elements and case halvesby welding as lead burning vor otherwise, as practiced in the art.

When the case halves are assembled, recesses 35 and 36 in case half I9and the corresponding reoesses in case half 20 form openings thatfurnish access to the interior of the cells. In the constructionillustrated these openings receive vent plugs I1 and I8.

After assembly of the elements and case halves and application of theterminals and intercell connector, the battery is ready for reception oithe electrolyte and formation or charging as now practiced in the art.

I have illustrated the improved case construction of the presentinvention employed in a twocell battery, but it is obvious that the samecase 'construction could be employed in batteries having any othernumber of cells as desired.

Figures shows a modified form of gravity indicator in whicheach casehalfhas a vertically eX- tending rib 49 molded integrally with the interiorof the side wall adjacent one vertical edge. The space between said riband the end wall half forms a trough for reception of gravity shapes 56,which may be similar to the gravity shapes il previously described.Shapes 50 may be retained Within the trough by a perforated plasticstrip 5I cemented to rib 49 and covering the open face of the trough,but permitting passage of electrolyte thereinto.

The two case halv-es are molded identically in this modied construction.Hence the gravity indicating devices appear at diagonally oppositecorners of the battery when the case halves are assembled with theiropen faces mating, and thus a gravity indicating device is furnished foreach ,cell in a two-cell battery.

The modied form of gravity indicator does not add to the overall lengthof the battery. Th-ere- ,fore its use is advantageous in batteries forinstallations in Which there is a length limitation.

Figures 5 to 8 show a modified form of terminal post and post seal inwhich flanges that fit both above and below the battery cover are castintegrally with the post. In these gures I have illustrated the post andseal applied to posts to which an intercell connector is attached, inwhich instance half portions of the connector are also cast integrallywith the posts. It is obvious, however, that similarly constructed postsand pcst seals may be employed for posts that form battery terminals, inwhich instance terminals may be cast integrally With the posts.

The posts, designated 52 and 53, are similarlyT formed. Said postsinclude integrally cast anges 54 that engage the under face of the coverhalves, anges 55 that fit above the cover halves, and connector means56, which in the illustration are halves of intercell connectors.Between post includes a cylindrical section 51 received within the coverrecesses and a section 58 having fiattened sides (Figure 7) toaccommodate plastic sealing wedges 59 (Figure 8). A gasket 54a of iresilient material such as, for example, soft rubber is interposedbetween flange 54 and the underside of the cover half.

As shown in Figure 8, the sealing wedges are bifurcated and thebifurcations taper outwardly.

The wedges are preferably employed in opposed pairs and are insertedbetween'flanges 55 and the upper face of the cover, one from either sideof the battery, after assembly `of the elements and case halves.Preferably they are cemented in place by suitable cement, such cementbeing similar to that mentioned above as suitable for cementing the casehalves together.

Either before or after assembly of the battery in the manner described,the two connector halves y56 are joined by welding, such as lead burningor otherwise, as indicated at 68.

Figures 9 and 10 show a modified form of terminal post and post seal inwhich provision is made for a grease cupsurrounding the post, a

feature thathas been found advantageous in preventing creepage ofelectrolyte. Figure 9 illustrates a post that carries a batteryterminal, but it is obvious that the same construction could be applied.to posts to which an intercell connector is attached.

As shown in Figure 9, the battery element has a terminal post 6| onwhich are integrally cast a lower flange 62, an intermediate flange 63,an upper flange 64 and connector means 65, which in this illustration isa battery terminal. The

cover halves t between the upper face of lower flange 62 and the lowerface of intermediate flange 63, a resilient gasket 62a being interposedbetween ange 62 and the underside of the cover. Flange 63 is surroundedby cement, indicated at 66.

Two plastic collar halves 61 are pieced together in abutting relationbeneath upper flange 64 and are retained by cement 66 to form an annularcollar surrounding said flange. The details of a collar half areillustrated in Figure 10. It is seen that said collar half includes abase portion 68 in the form of a half-annulus and an upstanding flange69 around the outer periphery of said base portion.

When the collar halves are cemented in place, there is sufficientclearance between the outer periphery of flange 64 on the post and theinner face of ange 69 on the collar to provide space for reception ofgrease indicated at 10. The use of grease for preventing electrolytecreepage is known in the art and hence is not explained here.

Figures 11 and 12 show a modied construction in which the intercellconnector is embedded in the battery cover. In this modification therecesses in the case halves are arranged somewhat differently than inthe embodiments of the invention illustrated in vFigures 1 to 10, butotherwise the case halves are similar to those of the embodimentsalready described.

`Only one case half is illustrated in Figures 1l and 12 and isdesignated 1|. It is to be understood that the other case half isidentically molded and hence has the same structural features. Y

It mates with case half 1I and is connected thereto in the same fashionas case halves I9 and 28.

`Case half 1| includes a side wall 12, cover half 13, partition half 14,and end wall halves and a bottom half, not shown, all molded integrally.

'The cover half contains a well 15 and the end walls of said well haverecesses 16 `and 11 for passage of the embedded intercell connector,

`hereinafter described.

lThe elements, designated 18 and 19, have ter- 'minal posts 80 and 8lwhich are offset from the 82 and 83. Side` walls 12 of the case half hasinwardly projecting brace lugs 84 and 85 molded integrally therewith onwhich shoulders82 and 83 of the posts rest to assistin supportingtheelements within the case, or the elements may be supported by properlyVlocatedribs as 21 and 28 of Figure l and Figure2.` Y. Horizontalextensions-86 .and81 `are cast in# tegrally withterminalposts-and 8l and:ex-

`tend into well 15 through recesses 16 and 11.

Half connectorsV 88 and 89 are cast integrally with said horizontalextensions.l `.After assembly of the elements, the connector halvesarejoined by lead burning or otherwise as practiced in `the are, thejuncture being. indicated at 10. After said connector halves are joined,the elements are assembled with the case halves. Well 15 is filled withsealing material, indicated at 9|, to embed the connector in theybattery cover. The sealing material `is preferably` non-rigid in orderthat it may yield and yet maintain intimate contact as the metal and'plasticcontract and expand at different rates in response4 totemperature changes( "Rubber or asphalt compositions are examples ofVsuitable materials. Preferably there is suicient clearanceV betweenextensions 86 and 81 and theedges of recesses 16 and 11 so that thesealing 4material at least partially lls said recesses. `v

When the case and connector areconstructed as illustrated in Figureslland `12,'the battery terminals may follow any of theconstructionspreviously described,'or they may extend through the ends of the batterycontainer in the same manner as connector `halves 86 and 81 extendthrough the well walls.

The expression #identically molded, as einployed herein, does notexclude` parts on which are performed subsequent operations .thatdestroy complete identicalism, as for example, a machining Voperation onone or both of the case sections. The expression mating sections is notlimited to identically molded sections,`but includes, for example,constructions in which one section is deeper than the other.` Theexpression connector means is intended to include either a batteryterminal or an"intercellconnector.or portion thereof.

From the foregoing description it is seen that I have provided improvedand simplified battery constructions in which battery cases are formedfrom identically molded mating case halves and I have also providedimproved terminal post constructions particularly adapted for use withsuch battery eases. It is obvious, however, that these principles ofconstruction shown may be applied to battery case sections which need:notbe of identical construction.``

` While I have shown but certain embodiments of the present invention,it is apparent that the structures may be further modified withoutdeparting from the spirit of the invention. Therefore I do not wish tobe limited `by the disclosure set forth, but only by the scope of the`appended claims. j

Iclaim: y ,1.

l. In a storage battery, a case and atleast one element, said casecomprising twoV preformed `mating case sections, said` case `sectionsincluding side walls, sections of end walls, `sections of a bottom andsections of a cover, said `ease sections having edge recesses, saidVcase sections being secured together at `their juncture, therebyforming walls, a bottom and a cover'enclo'sing said element,corresponding recesses in the case sec- Y battery. i f

2. In a storage battery,- a case and atleast one element, said casecomprising two preformed identically molded mating case halves, saidcase halves including integrally lformed side walls, halves of endWalls, halves of a bottom and halves of a cover, said case halves havingedge/recesses positioned symmetrically withrespect to the transversevertical center plane of the case halves, said case halves being securedtogether at their juncture, thereby forming walls, a bottom and a coverenclosing said element, corresponding recesses in the'case halvesregistering to form apertures through said case, said element havingterminal means passing through certainV of said apertures, another ofsaid `apertures `furnishing access to the interior of the battery. Y

3. In a storage battery, a case anda plurality or"Y elements, said casecomprising two preformed identically molded mating case halves, saidcase halves including integrally formed side walls, halves of end walls,halves of at least one partition, halves of a bottom and halves of acover, said case halves having edge recesses positioned symmetricallywith respect to the transverse vertical center planeof the case halves,said case halves being secured together at' their juncture, therebyforming Walls, at least one partition, a kbottom and a cover enclosingsaid elements in separate cell compartments, corresponding recesses inthe case halves registering to form apertures through said case, saidelements having terminal means passing through certain or saidapertures, intercell connectors joining certain of said terminal means,other of said terminal means forming battery terminals, other of saidapertures furnishing access to the interior of the cell compartments.

4. In a storage battery, a case and at least one element, said casecomprising two preformed mating case'sections, said case sectionsincluding side walls, sectionsY of end walls, sectionsv of a bottom andsections of a cover, the cover sections having edge recesses, said casesections being secured together at their juncture, thereby formingWalls, a bottom and. a cover enclosing vsaid eleinent,correspondingrecesses in the cover sections registering to form apertures throughsaid cover, said element having terminal vposts passing through certainof said apertures, another of said apertures furnishing access to theinterior oi? the battery.

5. In a storage battery, a case and a plurality of elements, said casecomprising two preformed identically molded mating case halves, saidcase halves including integrally formed side walls, halves of endwalls'halves of at least one partition, halves of a bottom and halves ofa cover, said cover halves having edge recesses, positionedsymmetrically with respect to the transverse vertical center plane ofthe case halves, said case halves being secured together at theirjuncture, thereby forming Walls, at least one-partition, a bottom and acover enclosing said elements in separate cell compartments,corresponding recesses in the cover halves registering to form aperturesthrough said cover, said elements having terminal posts passing throughcertain of said apertures, and intercell connectors joining certain ofsaid terminal posts externally of said case, yother of said terminalmeans forming battery fio , 8 terminals-other of said aperturesfurnishing access to the interior of the cell compartments.

6. In a storage battery, a case and aV plurality of elements, said casecomprising two preformed `mating case halves, said case halves includingside walls, halves of end Walls, halves of atleast one partitioirhalvesofV a bottom, haives of a cover and walls forming wells at theintersections of the partition halves vand cover halves, the well` meanspassing through the apertures in said Well walls, an intercellconne-:ter in said Well joining terminal means, and terminal means ontwo of said elements passing through apertures in said cover to formbattery terminals, other ofthe Vapertures in said cover furnishingaccess to the interior of the cell compartments.

7. In a storage battery, a case and a plurality of elements, said casecomprising two preformed identically molded case halves secured togethertheir juncture, thereby forming Walls, at least one partition, a bottomand a cover enclosing Asaid elei'nents in separate cell compartments,said case having apertures at the juncture of said case halves, saidelement having terminal means passing through certain of said apertures,and an intero-ell connector joining certain of said terminal means,other oi said terminal means forming battery terminals and other of saidapertures furnishing access to the interior of the cellcoinpartments. i

8. In a storage battery, a case andV atleast one element, said casecomprising two preformed identically molded case halves cementedtogether at their juncture, thereby forming walls, a bottoni and a coverenclosing said element, gravity indicating means, and means in said casefor housing said gravity indicating means.

il. In a storage battery, a case and at least one element, said casecomprising two preformed identically molded case halves having edgerecesses, said case halves being Vsecured together at their juncture,thereby forming walls, a bottom and a cover enclosing said element,corresponding recesses in the case halves registering to form aperturesthrough saidv case, said element having Vterminal means, at leastcertain of said erininal means having integrallyfor'med spaced pairs oilianges, said terminal means being received in said apertures with thecase edge between the flanges, and means sealing the outer iange to theexterior of the caseed'ge, another of said apertures being adapted tofurnish access to the interior of the battery.

l0. In a storage battery, a caseand at least one element, said casecomprising two preformed mating case sections, said case sectionsincluding integrally molded side walls, sections of end Walls, sectionsof a bottom, sections oa cover, and elements packing members projectingfrom said walls, said case sections having edge recesses, said casersections being' secured together at their juncture, thereby formingwalls, a-bottorn and a cover enclosing said element, the. elementpacking members compressing the plates and separators of theelernent,corresponding recesses in the case sections registering to formapertures through said case, said element having terminal meanspassingthrough certain of said apertures, another of said apertures furnishingaccess to the interior of the battery.

11. The method of assembling a storage battery comprising the steps ofinserting an element sidewise into a preformed case half with the postsextending through edge recesses in the case half, applying cement to theedge faces of the case half. and enclosing the element by tting a secondpreformed case half thereover.

12. In a storage battery including a plurality oi elements and a caseenclosing said elements, an interoell connector construction comprisingposts connected to said elements and having horizontal extensions, saidcase being formed of pre# formed mating sections secured together andhaving a well in the cover portion at the division between cells, theWalls of said well having edge recesses through vwhich said horizontalextensions pass. connector'means in said Well joining said extensions,andnon-rigid sealing material in said Well, covering said connectormeans.

j JOHN EDWARD WHITE.4

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Modern Industry, February 15, 1945, page 40.

